Thermostat



D. G. MERRILL Jan. 27, 1953 THERMOSTAT Filed May 27, 1950 INVENTOR DONALD 6. MERRILL N m m ATTORNEYS Patented Jan. 27, 1953 2562635? :IRHEBMOSIAT Donald G. Merrill, West Hartford, Conn assignor to Emhar't Manufacturing Company, a argoration of Delaware 11 31. nre 1- iq re a e ge er to meet thermostat te ratu rcefiirolle'rs and we e a t wla l t a erm mt o erp a tree Whi h-.991?! ,f a a r l' s r elem n a ta i eq wea -P e em 'l n closing of a valve to regulatepressurein "aufluid pressure line controlling the operation of a fluid mete q ad ustin the 't t i f i or effect of a heatin .Eflfififi j gal .o l'qih hea e strueture. H H Athermostat ortemperature controller of the typeabove-rnentioned is'disolosedin U S. Patent No; 1, 8 66;3 66i0f July-7; 1932, 'operatively applied to a 1e This ty eflof thermostat basedvantages "of simplicity and sensitivity. A disadvantage that T changes in temperature at the reference point "will cause "the leoiitrolled air pressure to vary between supply pressure and zeroeuickly so that the thermostat has a tendency tooperate on an off and on basis. The connected ..fluid "pressure motor will operate through its full range as a resultof avery small temperature change which may belessthanl" F., forexample, and of a pressure change through a rather limited part-of thefull pressure range.

Because of this extreme sensitivity, theeontrol tends to operate on either a ful1'on.or Ia full off basis and continually over-regulates instead of coming to rest aat some' balancledlregw lating position.

It is not desirable to decreasethe overall-sensitivity of such. a thermostat or controller as this could result in a sluggish action whenever in; ereased f rietio n in the motorsand valve meohanisr'n oceurr'ed. The eontrolled pressure'feurve desired, according "to thetpr'e'sent invention. is one withfsome spreadin the middleran'ge in which the control can ffloatfland lwithf definite limits beyondwhichpressure goes to amakirnum or to ew promptly. This desired result" is obtainedasfollow's. Instead of Venting/the valve direetly to; atmosphere,' its discharge is restrieted Jov an-secondary restrictedorifiee, provided in the exhaust line, sethat control-pressure doeslnot fall to; zero but levels off at someintermediate pressure depending on the ratfioof theareas of the eqondar -iestricte Or fi [i t am or bleed line andqaprimaryirestricted .or iiiceiin the pressurefs upplv' line, respectively. it will now require a much larger temperature change to give full travel to the connectedfluid pressure motor. The floating lrange. can be made longer orshorter as the leveling" off pressure is brought up to l or lowered ay from the fluid pressure m o p e at n -mns ,As a saiety faster and preferably, a second val'vef'and biz-pass connections around'the" seeo'ndary restricted orifice are provided so that pre u e-may rop d u ck WW0 by nihgthis seeond valve. This'may bedonew'hen the; departure from desired temperature 'reaeh'es aseleet'edvalu'e.

'When the departureoi temperature at-the reference point is in the reverse direction and the pressure starting point is2erb; the proeess of increasing the :control pressure to its "maximum will be just the reverseof that described-for decreasing ,the pressure from max mum to zero.

Further bbjectsfl'ejrld advantages of the 'inventionthereinaiter will-be pointed out or will be obvious from the followin description of a practical embodiment of the'finverition, as shown in thea'e' ornpanyihg drawings, in which:

Figfliis' 'a'view', m'ainlyin plan, with parts shown in section','of the'improved thermostat applied to "a' lehr, which is "indicated diagrammaticallyj Fig." 2 is a section along the 1ine 2-2 of Fig.1, showing details of the eontrolled fluidpressure line; i s V .t N

Fig. 3 is a view like Fig.;2but along the-line 3 3 0fFig/ 1;al1d I A I Big. 4 is a similar View but along the linegi -fl ofZEigl.

Thethermostat comprises a supportingplate 0r braoket I whichniayb e mountdjin anysuitable known manneron a side wallor'othr 'fiked 'p'art' of a lehr 2 or 'other 'heated" struoturein 'whieh the temperature" is? to be eont'iolle'di The supporting plate I is provided with a' threaded opening :3 with whioh the threaded open end portionfia of a tu es is engagedsothatsiich tubeprojects 'frorn the pla'te time the' leh'r' 'i or other heated structure. ""The tube 4 is inade of a high eiipansion heat e isting metal andy, such as nickel-Chrome steel; It'jis closed 'at its free end, whichji's loeated inithe lfehr, by' an erid wall indicated at 5b. Mounted at: the, outer side of the plate, i, as by beingipi'votally attached "at '5 to: outwardlyextending integral lug means E en the p1ate,,is allever l havinga limited" range of (swi n mo e ent t w rd an away frbmsueh plate. The lever "l oarries a'secohdary lever 8 Whioh is pivoted thereto are s es no best-in;- able in a slotted or open-workportion 'ld ofth e main lever i about an axis parallel to the axis 6f piv a mo emen s of v h gr i in' eve i 1 a ward-and away frorn the outer open end of he tube 4. The secondary lever 8 earris an ad- ;fust ne c ws whi h i epe 1 r1ialisndfitit the tube 4 and is formed with an axial bore or cavity II open at the end thereof next to the outer end of the tube 4 and extending into the head I2 of such adjusting screw. In the example shown, the head I2 has been formed separately from the shank of the adjusting screw and is screw-threadedly attached thereto.

The internal bore II of the screw includes a relatively enlarged portion Ila in the head I2 to accommodate a relatively enlarged outer end portion I3a of a rod I3 which extends from the bore of the adjusting screw III into and in the bore of the tube 4 to the end wall 4b of such tube so as to push axially against such end wall. The rod I3 is of a low expansion heat resisting alloy, as for example, chrome steel. It is moved axially relative to the tube 4 as the latter expands and contracts in length in response to temperature changes in the lehr where such tube is located. A ball bearing I3b may be interposed between the enlarged outer end portion |3a of the rod and head of the screw III at the outer end of the bore I I. The means for maintaining the rod I3 pushed axially against the end wall 4?) of the tube 4 may include a relatively coarse adjusting screw I4 threaded through an apertured integral lug I5 in the slotted portion Ia of the main lever I to bear against the outer side of the secondary lever 8 at a point intermediate the pivotal axis 9 and the adjusting screw ID, the latter being near the free end of the secondary lever. The main lever I has a relatively short end projection Ib at the opposite side of its pivotal axis 5 from the lever proper. A coil spring I6 is compressed between the lever end portion 'Ib and the adjacent portion of the supporting plate I so as to urge the lever I toward the supporting plate I. The rod I3 thus will be urged continuously toward the closed end of the tube 4. The extent to which the lever I will be swung at any given time toward the supporting plate I by the action of the spring I6 will be determined by the adjustment of the screws I0 and I4 and the relative lengths of the rod I3 and tube 4. The screws I0 and I4 are adjusted as hereinafter explained to calibrate the device when it is installed and placed in operation.

The lever I has a free end portion To extending beyond the apertured or open-work portion Ia. Two adjustable valve actuating elements in the form of screws I1 and I8, respectively, are mounted in longitudinally spaced, screwthreaded openings I9 and 20, respectively, in the free end portion 1c of the lever I. The screws I1 and I8, respectively, are located in line with plungers 2| and 22, respectively, projecting from parallel openings 23 and 24, respectively, in a valve block 25 which is mounted on one end of the supporting plate I in opposing relation to the free end of the lever I. The valve block 25 is is bored to provide parallel valve chambers 26 and 21, respectively, of two pressure control valves which generally are designated A and B, respectively. The valve chambers 26 and 21 are continuous with the openings 23 and 24, respectively, and are formed to provide seats 26a and 21a, respectively, for ball valves 28 and 29. The valve seats 26a and 2111 are located intermediate the ends of valve chambers 26 and 21 and face away from the openings 23 and 24. Compression coil springs 3|] and 3|, respectively, are provided in the valve chambers to press against the ball valves 28 and 29 so as yieldingly to maintain them on their seats.

The plunger actuating screws I1 and I8 may be adjusted to project from the lever I to the same extent or to different extents. The arrangement is such in any event that a swinging movement of the free end of the lever I toward the valve block 25 will first act through the plunger 2| to move the ball valve 28 of the valve A from its seat while the valve B remains closed. A further movement of the lever I toward the valve block will cause unseating of the ball valve 29 to open the valve B. The purpose and efiect of this delayed opening of the second valve will be explained.

A passage 32, Fig.2, extends in the valve block from one end thereof to a point adjacent to the valve chamber 21. A pressure fluid supply pipe 33 is operatively connected with the outer end of passage 32 by a suitable pipe fitting 34. The pipe 33 may receive air or other fluid from a source of pressure fluid supply, not shown. A constant pressure outlet regulating valve 35 and air filter 36 may be provided in the pressure fluid supply line between the source and the valve block 25. The passage 32 communicates through a short lateral connecting passage 3! with the valve chamber 21 at a level above the ball valve in the latter. See Fig. 4. A short connecting passage 38 connects the upper portion of the valve chamber 21 with the corresponding portion of the valve chamber 26. From the upper portion of the valve chamber 26, a short passage 39 leads through the remainder of the valve block to the opposite end thereof from that provided with passage 32. Outer end of passage 39 is connected, as by suitable pipe fitting 40, with a pressure fluid delivery pipe 4|. The delivery pipe 4| leads to and is operatively connected to a pressure fluid motor 42 which may be a spring type diaphragm motor. The projecting stem 42a of this motor is connected to operate a movable part, shown as a lever 43, which may be considered as representative of the adjusting means of any known heating system, damper system or the like which may be operatively applied to the lehr or other heated structure, the temperature in which is to be controlled in response to variations of temperature at the control point where the temperature responsive element 4, I3 is located. The line 4| may be provided with a suitable pressure gauge 44.

The pressure fluid supplied by the line 4| to the air motor 42 will operate this diaphragm motor 42 in the usual way against a spring 42b of the motor to swing the lever 43 to a position determined by the pressure of the pressure fluid. As this pressure is increased from zero it reaches some value suffieient to overcome the pressure of the extended spring causing the lever to move away from its extreme inward position. A further increase in pressure will cause a further compensating compression of the spring so that the lever takes a new position. At a sufficiently high pressure which is preferably considerably below the supply pressure, the lever takes up the extreme outward position. Within this range of pressures in which the lever moves from one extreme to the other there is for each value of the control pressure a corresponding deflection of the spring 42b and a corresponding position of the lever 43. The means for and manner of regulating the control pressure will now be described.

An exhaust line in the valve block 25 includes a passage 45, Fig. 3, opening through one end of the valve block and there connected by a suitable pipe fitting 46 with an external venting or accents exhaust pipe 41. The passage-45 is connected by a short lateral passage 48 with a lower portion of the valve chamber 21 at a level below the valve "seat 21a as best seen "in Fig. 4. The passage 45 has an extension, indicated at 49, Fig. 3, in the valve block 25,- connectedby a short lateral passage 59 with the lower portion of the valve chamber 26.

A restriction is placed in the pressure fluid supply line in the block '25 between the "pressure fluid supply passage 32 and the valve chamber Z'l. This restriction is provided in the example shown by inserting 'a' screw'5l across the passage 32 into the'passage 3-1,"Fig. 2, so that communication between-the passages and 31 'is' through a restricted orifice'ill, called the "primary orifice, providedin the'screw 5|. The screw-5| -may-be removed for cleaning.

A restriction'also is placed in theexhaust line in the block '25 between-the lower portion cf the valve chamber 26 and the passage '49. This also is provided by inserting a screw '53 across the passage '49 into the connecting "passage 50, the screw 53 having a restricted orifice 5'4, called'the secondary orifice. 'See Fig. 3.

In operation, fiuidpressure from the supply line 33 communicates through primary orifice 52, upper "portions of valve chambers 2! 'andzt in turn'and thence through passage 39 'with delivery pipe 4|. If valves A and B remain closedfthere will be no flow past orifice 52 and full supply pressure will be maintained on "pipe 4| andair motor '42. As valve A is lifted slightly, there will be some fiow past bal1 28 and through orifice 54 and the pressure in passage 39 will assume a value depending on the relative areas of primary orifice 52 and secondary orifice 54 and the amount of opening of valve A. As valve A opens further, the pressureiin passage 39 will fall to a value determined only by the sizes of 0rifices52 and 54 which value may be chosen at or near the pressure which corresponds to extreme inward position of air motor lever. By this means, the motion of valve A, which is necessarily very small, is made to correspond to the restricted pressure range of actual .air motor operation instead of to the full range from.zero to supply pressure. The change in control pressure is therefore much smaller foreachdegree of temperature change and any ,tendency .to overshoot is therefore overcome. ,By suitablechoice .of orifice sizes, thecontrol pressure andthe movements of lever -43 can be made to correspond closely to the temperaturedepartures and heat supplychanges will be made. in correct amount to restore temperature equilibrium. The .control devices will therefore float within thecontrol range, making compensating. motions proportional to the departure of temperature from the set value instead of continually swinging from one extreme'position to the other.

Since the accuracy of the described adjustments are adversely affected by frictionin the moving parts and by dirt particles in the fluid passages, it'is desirable to insure travel to either extreme position when temperature departure reaches certain values. Travel to extreme outward position is insuredby maintaining supply pressure well above that normally required to fully compress the spring 422). Travel to extreme inward position is insured as follows. Adjustment of screw I8 is such that valve B begins to lift when the desired upper limit of temperature is reached. This places delivery pipe 4| in direct communication with vent pipe 41 by means of 6 passages '39, 2 1, 21a, and 45. Thecontrol pressure thendrops-to zero whichisoonsiderablytless than'the pressure required to balance the spring. This leaves a large-excess of COIHDIGSSiOILiIlwthB spring to insure trave1 to the extreme inward position.

The device may be setto maintain a desirable temperature at the place in the ilehr.;or .:other structure at which'the temperaturezis :to be controlled by first adjusting the coarse adjusting screw M. to an appropriate extent asindicated-by the judgment of the operator in the light of his knowledge of the conditions involved :and then making further and finer adjustments if required by adjustments of the adjusting screw l0 alone or of both adjusting screws until the :temperature at the controlled place coincides i-with that desired, this information being obtained by reading a suitablyplaced pyrometer or inany other suitable known manner. The head of the coarse adjusting screw it isprovided with a peripheral scale 55, the graduations of which have values related to those of a pyrometer or other temperature measuring instrument. An index element 55 may be provided on a fixed projection 57 on the lever 'l' in cooperative relation to the scale A similar peripheral scale 58, cooperative with an index element 59 on the projection 5'1, may beprovided on the head of the fine adjusting screw it. To calibrate .the; device after it has been set to maintain a desirable temperature in the manner described,'the coarse adjusting screw Hi and the fine adjusting screw it which of course have reverse positionin'gactions on the lever system may be given mutually compensating turning movements about their respective axes until the scale 55 on the head of the coarse screw it and its cooperative index element show the temperature which the device is set automatically to maintain. Changes of setting by known amounts to maintain temperatures differing from that of the previous setting .can now be made by adjusting the coarse adjusting screw it as indicated by the scale 55 thereon. Fine adjustments by the fine screw 15 andreference to the scale 58 thereon may be made from time to time to correct any discrepancy between the reading of the scale 55 and the corresponding pyrometer reading or in the event that calibraticn has been destroyed for any cause, as :by creep in the expansion elements which will occur over a period of time, readjustment of the control valves to suit operation requirements, disassembly of the parts of the valve block for cleaning or other purpose, etc. By providing the fine and coarse adjusting screws and-providing scales suitable to indicatetemperature values, the calibration may be readily effected upon installation and again thereafter if needed.

Many changes in and modifications of the illustrative embodiment of the invention shown in the accompanying drawings and herein [particularly described will now be obvious to those skilled in the art'and I therefore do not wish-to be limited to the details of this embodiment.

I claim:

1. A thermostat comprising a fluid pressure supply line for conducting fluid" pressure froma source of supply to a'fiuid pressuremotor, a fixed restriction in the supply line defining a primary restricted orifice therein, a fluid pressure exhaust line operatively connected to the supply line between the primary orifice and said motor, a fixed restriction defining a secondary restricted orifice in said exhaust line, a valve in said exhaust line adapted when closed to shut ofi exhaust of fluid pressure from the supply line through the exhaust line and to permit such exhaust when opened, a thermo-responsive element, means responsive to said thermo-responsive element to control the opening and closing of said valve, and a second exhaust valve and connections with the supply line and exhaust line by-passing said first valve and said secondary restricted orifice.

2. A thermostat as defined in claim 1 wherein said valves are arranged to be opened in a predetermined sequence by said means responsive to said thermo-responsive element.

3. A thermostat as defined by claim 2 wherein said first mentioned valve is opened before and closed after said second valve.

4. A thermostat comprising a fluid pressure supply line to conduct fiuid pressure from a source of supply to a fluid pressure motor, a fluid pressure exhaust line having a portion adjacent to a portion of the supply line, two exhaust valves having separate valve chambers each connected at one end with the supply line and at the opposite end with an adjacent portion of the exhaust line, each valve having an intermediately located seat and a cooperative movable valve member in its chamber, the valve member being adapted when seated to cut off flow of fiuid pressure through the valve chamber from the supply line to the exhaust line and to permit such fiow when unseated, each of said valves having an opening at the end of its chamber remote from the supply line, spring means yieldingly holding each valve member on its seat, a valve member unseating plunger movable in the portion of each chamber remote from the supply line and protruding therefrom, a restriction in the exhaust line between its connections with the chambers of said two valves, a pivoted lever to actuate said plungers to unseat said valve members in sequence against the pressure of their springs, and a thermo-responsive element arranged to actuate said lever to effect unseating of said valve members on a predetermined change of temperature afiectmg the thermo-responsive element.

5. A thermostat comprising a supporting plate, a valve block carried by said supporting .plate at one end thereof, a pressure fluid supply line having a portion extending through said valve block and adapted to conduct fluid pressure from a source of supply to a fluid pressure motor, an exhaust line having a portion extending into said valve block in spaced adjacent relation to a portion of the supply line, two exhaust valves in said valve block separately connecting the portions of the supply line and exhaust line in said block, said valves being normally closed to prevent flow of fluid pressure from the supply line to the exhaust line and having movable valve opening plungers projecting from the valve block, a restriction in the exhaust line between said two exhaust valves, a lever pivoted to said supporting plate to swing in a path extending across the projecting ends of said valve opening plungers, a thermo-responsive element carried by said supporting plate, and adjustable meansoperatively connecting said thermo-responsive element with said lever to operate the latter to actuate said plungers to open said valves sequentially on a predetermined change of temperature affecting the thermo-responsive element.

6. A thermostat as defined by claim 5 wherein said lever includes separate individually adjustable contact elements in line with the projecting ends of the plungers to time the actuation of said plungers by a swinging movement of said lever.

7 A thermostat as defined by claim 5 wherein said thermo-responsive element comprises a tube of heat resisting high expansion material carried by said supporting plate to project from the side thereof opposite said lever, said tube being closed at its end remote from said plate and a rod of heat resisting low expansion material extending in the tube against the closed end thereof and projecting from the supported end of the tube at the same side of the supporting plate as said lever, a secondary lever mounted on the first lever, a hollow adjusting screw carried by said second lever to bear against the adjacent end of said rod, a second adjusting screw carried by said first lever to bear against the second lever in opposition to said first adjusting screw, and spring means acting on the first lever to tend to swing it against the plungers projecting from said valve ock.

8. A thermostat comprising a supporting plate having a threaded opening in a portion thereof, a tube of heat resisting high expansion material mounted at one end in said opening of said supporting plate to project from one face of the supporting plate, said tube being closed at its projecting end, a rod of heat resisting low expansion material extending in said tube to the closed end thereof and projecting from the opposite face of the supporting plate, a main lever pivoted on said supporting plate to swing toward and away from the face thereof opposite said projecting tube and adjacent to the projecting end of said rod, a secondary lever pivoted on said main lever, a hollow fine adjusting screw carried by said secondary lever so as to fit over the projecting end of said rod, a compression spring arranged between the main lever and supporting plate so as to urge said lever to swing toward said plate, a coarse adjusting screw carried by the main lever to bear against the secondary lever in opposition to said fine adjusting screw and cooperative with said compression spring acting on the main lever to maintain said fine adjusting screw pressed firmly against the projecting end of said rod, temperature regulating means operable by said main lever on swinging movements thereof in response to expansion and contraction of said tube in relation to said rod, and peripheral scales on the heads of said adjusting screws and cooperative index elements on said main lever for use in calibrating the thermostat.

DONALD G. MERRILL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,805,971 Bristol May 19, 1931 2,029,203 Soderberg Jan. 28, 1936 

